Pivoting grass catcher attachment to self-propelled power mower

ABSTRACT

A grass catcher for attachment to a power mower. In certain embodiments, the grass catcher is mounted to a self-propelled power mower so that the catcher is pivotable about two substantially perpendicular axes simultaneously.

This is a continuation of application Ser. No. 09/054,472, filed Apr. 3,1998, now U.S. Pat. No. 6,044,634, the entire content of which is herebyincorporated by reference in this application.

This application relates to a grass catcher for attachment to a lawnmower. More particularly, this invention relates to a side-mountablegrass catcher pivotally attachable to a self-propelled mower so that incertain embodiments there is no need to mount an additional supportbracket to a cutter deck adjacent the grass discharge opening.

BACKGROUND OF THE INVENTION

Grass catchers for attachment to self-propelled commercial walk-behindpower mowers are known in the art. Typically, grass catchers have beendesigned so that they can only be attached to the mower adjacent a sidegrass discharge opening when an additional support bracket is affixed tothe cutter deck. The need to attach additional bracketry to the mower isundesirable and burdensome. Still further, certain prior art catchersand mowers are designed such that the catcher can only be attached tothe cutter deck of a mower if the chute deflector is removed from themower.

It is apparent from the above that there exists a need in the art for agrass catcher which is designed in a manner such that for certain typesof walk-behind mowers, there is no need to provide additional bracketryprior to grass catcher attachment. In alternative embodiments, such acatcher can also be mounted to the side of stand-on zero turning mowers.There is also a need in the art for a grass catcher design which whenutilized with certain types of mowers eliminates the need to remove achute deflector prior to grass catcher attachment.

This invention will now be described with respect to certain embodimentsthereof, accompanied by certain illustrations.

SUMMARY OF THE INVENTION

Generally speaking, this invention fulfills the above-described needs inthe art by providing a system for mounting a grass catcher to aself-propelled power mower including a cutter deck, the systemcomprising:

the cutter deck including a side discharge opening defined thereinthrough which grass cut by the mower is thrown;

a support member extending upwardly from a plane of the cutter deck, thesupport member including first and second sidewalls and a top;

said support member including a mounting aperture defined therein;

the grass catcher including a male mounting member and a ramp member,the male mounting member fitting into the mounting aperture defined inthe support member and the ramp member engaging a portion of the supportmember when the grass catcher is mounted on the mower; and

wherein the grass catcher includes a grass input opening defined thereinfor allowing grass to enter the catcher from the side discharge openingwhen the catcher is mounted on the mower.

This invention further fulfills the above-described needs in the art byproviding a grass catcher comprising:

a frame including a plurality of elongated members;

material disposed between elongated members of the frame for at leastpartially enclosing an interior of the catcher, the interior for holdinggrass that is output through a grass discharge opening;

an elongated male pin for insertion into an aperture defined in aportion of the mower, the elongated male pin including at least firstand second portions which are angled relative to one another, with thefirst portion extending substantially perpendicular to a side of thecatcher from which it projects;

a latch affixed to the catcher, the latch including at least a firstportion and a second portion which are connected and angled relative toone another, the first portion be oriented substantially parallel tosaid side of the catcher and the second portion having an underneathsurface for resting upon a support of the mower when the catcher ismounted on the mower.

This invention will now be described with respect to certain embodimentsthereof, along with reference to the accompanying illustrations.

IN THE DRAWINGS

FIG. 1 is a side elevation view of a self-propelled power mower, withouta grass catcher attached thereto.

FIG. 2 is a top view of the cutter deck of the FIG. 1 mower, the FIG. 2cutter deck adapted to receive a grass catcher according to anembodiment of this invention.

FIG. 3 is an exploded perspective view of a grass catcher which isattachable to a corresponding cutter deck of a self-propelled powermower according to an embodiment of this invention.

FIG. 4 is a cross-sectional view illustrating the securing ramp (orlatch) of the FIG. 3 grass catcher extending over top of a support barprovided on top of the mower's cutter deck, in accordance with the FIG.3 embodiment of this invention.

FIG. 5 is a cross-sectional view of the angled pivot pin of the FIG. 3grass catcher extending through an aperture defined in the correspondingsupport member which is affixed to the top of the cutter deck inaccordance with the FIGS. 3-4 embodiment of this invention.

FIG. 6 is a front elevation view illustrating the cutter deck andcorresponding catcher in accordance with the FIGS. 3-5 embodiment ofthis invention, wherein the catcher is being pivoted upward due tocatcher contact with the ground thereby preventing scalping of turf.

DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS OF THIS INVENTION

Referring now more particularly to the accompanying drawings in whichlike reference numerals indicate like parts throughout the severalviews.

FIG. 1 is a side plan view of a self-propelled stand-on zero radiusturning power lawn mower to which a grass catcher in accordance withcertain embodiments of this invention may be attached. The FIG. 1 mowerincludes a pair of rear independently driveable wheels 1, a pair offront pivotal caster wheels 3, cutter deck 5, side grass dischargeopening 7 defined at a side of cutter deck 5, engine 9, rigid handle barmember 11, thigh pad 13, support member 15, reverse handle controlmember 17, forward handle control member 19, and pivot axis 21 aboutwhich members 17 and 19 may pivot. The FIG. 1 mower may be a stand-onmower as illustrated including foot platform 23 for supporting astanding occupant, or alternatively in other embodiments may be awalk-behind self-propelled mower as known in the art.

FIG. 2 is a top view of cutter deck 5 of the FIG. 1 mower. Asillustrated, cutter deck 5 includes planer surface 25 below which aremounted a plurality of cutting blades (not shown). Apertures 29 areprovided in the plane of cutter deck 5 so that driving spindle members(not shown) can extend downwardly from pulleys in order to drive thecutting blades. Cutter deck 5 further includes vertically extendingsupport wall 31 which partially closes off the belt area, andcorresponding support walls 33. A cover (not shown) may be mounted ontop of walls 31 and 33 to enclose the belt area. The cutter deck 5 maybe attached to the other portion of the mower assembly by way of supportmembers 35.

Still referring to the FIG. 2 cutter deck, grass discharge opening 7 isdefined in a side thereof. Located at an edge of top plane 25 of cutterdeck 5 immediately adjacent and above grass discharge opening 7 isvertically extending rigid metal support member 37. Support member 37 isprovided with grass catcher mounting aperture 39 defined therein, andchute attachment members 61 are located proximate member 37.

Referring now to FIGS. 2-6, it will be explained how grass catcher 41 isdesigned and how the catcher is affixed to the mower adjacent sidedischarge opening 7. As illustrated in FIG. 3, grass catcher 41 includesa frame portion made up of elongated rigid members 43-49 and 65.Elongated members 43-49 and 65 may be welded together at corner orjunction areas according to certain embodiments of this invention, witheach member 43-49 and 65 being made up of hollow metal tubing. Members43-49, may each be independent and distinct members welded together oralternatively the entire frame may be made up of one, two, three, orfour integrally formed pieces. Screen or mesh 51 is provided between theframe members so that catcher 41 can hold grass which is thrown or blownthereinto. According to certain embodiments of this invention, sheetmetal 53 is formed adjacent opening 55 in the grass catcher, with sheetmetal 53 being present in areas of the catcher which are exposed todirect impact of incoming grass. When catcher 41 becomes full of grass,its may removed from the mower and emptied as will be described below.Grass catcher 41 is designed so that opening 55 defined therein ismounted proximate or immediately adjacent grass discharge opening 7 sothat grass cut by the mower can be blown out of the cutter deck throughopening 7 and into grass catcher 41 through input opening 55. In certainembodiments, sheet metal 53 and screen or mesh 51 may be made ofappropriately formed 22 gauge steel sheet, or the like. Other materialsmay of course suffice, depending upon the application or cost of thecatcher. Also, in certain embodiments, frame members 43-49 and 65 may bemade up of, for example, 5/8" square steel or metal tubing.

Typically, certain mower cutter decks 5 are provided with a verticallyextending elongated wall or support member 37 as illustrated in FIGS.2-4. Vertical deflection chute mounting members 61 may also be provided.An aperture or hole(s) 39 is defined in each support member 37 near thefront (or rear in certain embodiments) of the grass discharge opening 7.Aperture 39 is adapted to receive elongated angled pin or angledprojection member 63 provided on catcher 41 (see FIGS. 3 and 5).

When grass catcher 41 is mounted to cutter deck 5 by way of bent orangled pin 63 being provided in mounting aperture 39, the pin 63 and/oraperture 39 represent(s) a pivot axis about which catcher 41 can pivotas illustrated in FIG. 6. Such pivoting is useful in mounting thecatcher on the mower, removing the catcher from the mower, and inenabling the catcher to float or change positions during mower operationso as to prevent grass scalping. For example, as shown in FIG. 6, whenthe mower runs over bumpy or hilly terrain which contacts the bottom ofgrass catcher 41, the catcher is permitted to pivot upward about thepivot axis defined by pin 63 and/or aperture 39 so as to avoid scalpingof grass. This pivot axis is defined by an axis extending throughmounting aperture 39.

Grass catcher 41 includes rigid elongated horizontal support member orbar 65 which extends between and is connected to substantiallyvertically +/-30 degrees oriented frame members 45 and 47. Ramp supportbracket 67 is mounted to elongated support member 65, e.g. on a majorsurface thereof, as illustrated in FIGS. 3-4. Bracket 67 includes asubstantially planar major surface which faces the cutter deck and has aplurality, or row, of mounting apertures 69 defined therein for thepurpose of enabling ramp or latch member 71 to be mounted to bracket 67at different select locations. Because two mounting apertures aredefined in ramp 71, the ramp may be affixed to bracket 67 at a pluralityof different locations thereon (i.e. using any two mounting apertures69). Thus, the position of ramp 71 on bracket 67 may be adjusteddepending on the type of lawn mower to which catcher 41 is to beattached.

As illustrated in FIG. 4, ramp or latch 71 is attached to bracket 67 byway of a fastener 73 such as a nut and corresponding bolt. Two suchfasteners 73 are utilized in view of the two independent mounting holesprovided in ramp 71 for mounting. Furthermore, as illustrated in FIG. 4,ramp 71 includes three separate integrally formed portions, namely flatportion 107 for mounting to bracket 67, flat portion 103 for keeping theramp from slipping over wall 37 during mower operation, and angledportion 71 which connects portions 103 and 107 to one another. Ofcourse, ramp 71 may be in the form of other shapes. For example, ramp(or latch) 71 may be substantially z-shaped, curved, substantiallystair-shaped, or the like.

The plurality of apertures 69 enable the catcher to be adjustable to fita number of different commercially available mowers, such as knownBobcat 36", 48", and/or 52" walk-behinds, and known Exmark 36", 48", and52" walk-behinds.

When it is desired to mount grass catcher 41 on cutter deck 5, anoperator first manipulates the catcher so that angled pin 63 is causedto be inserted into and through aperture 39. Then, the operator pivotsgrass catcher 41 upwardly about the pivot axis defined by pin 63 inaperture 39 until bottom edge 81 of ramp 71 can fit over top of top edge83 of support 37. Then, grass catcher 41 is pivoted about a verticalaxis proximate the front of the mower deck so as to be pressed closelyadjacent grass discharge opening 7 in deck 5 so that ramp 71 extendsover top of support 37. Then, the grass catcher 41 is dropped, orpivoted downward about the axis defined by pin 63 in aperture 39 so thatthe underneath or bottom surface 87 of ramp 71 comes to rest on part(e.g. corner) of the top edge 83 of support 37 as shown in FIG. 4. Whenthis is done, grass catcher 41 is properly mounted on the mower viaangled pin 63 in hole 39, and ramp or latch 71 which maintains thecatcher on is the mower. Both the angled portion of pin 63 and ramp 71keep the catcher from falling off of the mower.

Catcher 41 and the corresponding structure illustrated in FIGS. 3-6 aredesigned so that, during mower operation and during catcherattachment/removal, catcher 41 can pivot about first and second pivotaxes which are substantially perpendicular to one another. The firstsuch pivot axis 91 (see FIGS. 3 and 5) is defined by a portion of pin 63protruding through aperture 39. Although the center line of pivot axis91 may be adjusted during operation due to the loose fit of pin orprojection 63 relative to the surrounding inner diameter of aperture 39,axis 91 typically remains substantially parallel ±20° to the groundwhich may be considered horizontally aligned, and axis 91 extendsthrough aperture 39 at some point. The second pivot axis 93 about whichthe catcher can pivot during mower operation is substantiallyperpendicular to axis 91, and is defined adjacent top edge 83 of support37 as shown in FIGS. 3-4. Because of the way in which ramp 71 fits overtop 83 of support or wall 37 as shown in FIG. 4, the catcher may pivotabout axis 93 so that the portion of the catcher above the cutter deckand closest to the mower pivots inwardly toward the mower's engine asillustrated in FIG. 6. Thus, for example, when the bottom of catcher 41contacts the ground as shown in FIG. 6, the bulk of the catcher cansimultaneously pivot upwardly 101 about axis 91 and inwardly 103 towardthe mower about axis 93. Bend or angled portion 99 of male member or pin63 keeps the catcher mounted to the deck 5 during such pivoting. Bend 99typically defines an angle θ relative to straight portion 101 of pin 63of from about 20°-70°, preferably from about 30°-55°.

Catcher 41 is installed and removed from the mower by pivoting thecatcher about both axis 91 and axis 93. Such dual pivoting is unlikelyto occur during operation of the mower. Thus, catcher 41 is designed soas to be easily installed and easily removed from the mower, yet preventunwanted detachment of the catcher during mower operation. Substantiallyflat portion 103 of ramp 71 is provided to keep the catcher from slidingoff of the mower at the end of the ramp, while angled portion 105 oframp member 71 maintains the catcher tightly against the side of deck 5adjacent the grass discharge opening and allows the catcher to pivotabout axis 93 during mower operation. Flat portion 103 typically definesan angle θ relative to angled portion 105 of from about 30°-60°, andpreferably from about 35°-50°. Angled portion 105 of ramp 71 further isintegrally formed with flat portion 107, with flat portions 103 and 107being substantially parallel to one another in certain embodiments ofthis invention.

It is noted that vertically extending support member 37 is providedimmediately adjacent, or at least closely adjacent the edge of deck 5proximate the grass discharge opening. This enables the catcher, viaramp 71 and pin 63, to be held flush or closely provided adjacent thegrass discharge opening of deck 5 so that substantially all grass cut bythe mower and thrown through opening 7 is received within the interiorof catcher 41. The design of the mower also permits the catcher, whenpivoted upward about axis 91 or inward about axis 93 during moweroperation, to be biased back toward the fundamental resting attachedposition shown in FIG. 4.

For mowers which do not have a support member 37, it is within thepurview of this invention to anticipate that owners or dealers of suchmowers may add a support member similar to member 37 shown herein, sothat grass catcher 41 can be attached to the mower via a ramp or latch71 and male member 63.

Furthermore, with certain mowers, in view of the catcher designdescribed herein, it is unnecessary to remove the plastic or rubberpivoting chute deflector which is typically provided adjacent the grassdischarge opening. This chute deflector is typically affixed to themower via apertures defined in vertical members 61. For example, such achute is described and illustrated in commonly owned pending U.S. Ser.No. 08/972,395, filed on Nov. 18, 1997, the entire disclosure of whichis incorporated herein by reference. Also, if a particular mower doesnot have aperture 39 defined therein when purchased, then it isanticipated that a user could drill such a hole 39 in a support member37 so as to enable the mower to accept mounting of catcher 41.

Once given the above disclosure, many other features, modifications, andimprovements will become apparent to the skilled artisan. Such otherfeatures, modifications, and improvements are, therefore, considered tobe a part of this invention, the scope of which is to be determined bythe following claims.

What is claimed is:
 1. A grass catcher to be mounted to a side grassdischarge opening of a self-propelled lawn mower, the grass catchercomprising:a frame; a cavity at least partially defined by the frame andat least partially enclosed for holding grass that is output through theside grass discharge opening; an elongated projection for insertion intoan aperture defined in the mower; a latch affixed to the catcher, thelatch including at least a first portion and a second ramp portion whichare connected to one another so as to define an angle of from about30-60 degrees therebetween, the second ramp portion having a surface forresting upon a support of the mower when the catcher is mounted on themower; and wherein said projection and said latch enable the catcher tosimultaneously pivot about first and second different axes during moweroperation, wherein said first and second axes are approximatelyperpendicular to one another.